ORTHODONTIC APPLIANCE AND METHOD OF FORMING AND APPLYING SAME

Abstract

An orthodontic appliance includes an indirect bonding tray; at least one bracket segment integrally formed with the indirect boding tray; an integral slot location feature formed in the at least one bracket segment; a support structure configured to be bonded with the at least one bracket segment and wherein the integral slot location feature is configured to positively orient the support structure relative to the at least one bracket segment, the support structure being further configured to retain an arch-wire; and wherein a weakened section joins the indirect bonding tray and the at least one bracket segment, the weakened section being configured to facilitate removal of the indirect bonding tray from the at least bracket segment after installation of the at least one bracket segment. An associated method of creating and installing the orthodontic appliance is also disclosed.

Claims

1. An orthodontic appliance, comprising: an indirect bonding tray; at least one bracket segment integrally formed with the indirect boding tray; an integral slot location feature formed in the at least one bracket segment; a support structure configured to be bonded with the at least one bracket segment and wherein the integral slot location feature is configured to positively orient the support structure relative to the at least one bracket segment, the support structure being further configured to retain an arch-wire; and wherein a weakened section joins the indirect bonding tray and the at least one bracket segment, the weakened section being configured to facilitate removal of the indirect bonding tray from the at least bracket segment after installation of the at least one bracket segment.

2. The orthodontic appliance as set forth in claim 1, further comprising an adhesive agent configured to secure the support structure with the at least one bracket segment and the at least one bracket segment to a tooth surface.

3. The orthodontic appliance as set forth in claim 1, wherein the weakened section comprises a narrowed section of material provided with a smaller cross-sectional area relative to the indirect bonding tray.

4. The orthodontic appliance as set forth in claim 1, wherein the weakened section comprises a perforated section of material.

5. The orthodontic appliance as set forth in claim 1, wherein the at least one bracket segment is provided with at least a lingual surface and a tooth-facing surface and wherein the integral slot location feature is provided on the tooth-facing surface.

6. The orthodontic appliance as set forth in claim 1, wherein the at least one bracket segment is provided with at least a lingual surface and a tooth-facing surface and wherein the integral slot location feature is provided on the lingual surface.

7. The orthodontic appliance as set forth in claim 1, wherein the support structure comprises a tube configured with a cross-sectional shape corresponding to a cross-sectional shape of an arch-wire inserted through the support structure.

8. The orthodontic appliance as set forth in claim 7, wherein the support structure comprises a rectangular tube.

9. The orthodontic appliance as set forth in claim 7, wherein the support structure comprises a metallic tube.

10. The orthodontic appliance as set forth in claim 2, wherein the adhesive agent is a flowable light cured resin.

11. The orthodontic appliance as set forth in claim 2, wherein the at least one bracket segment, integral slot location feature, support structure, and adhesive agent form a bracket and wherein the adhesive agent comprises no more than approximately 10% of a mass of the bracket.

12. The orthodontic appliance as set forth in claim 1, further comprising a second integral slot location feature and a second support structure and wherein the second integral slot location feature is configured to positively orient the second support structure relative to the bracket segment.

13. The orthodontic appliance as set forth in claim 1, wherein the support structure and the integral slot location feature are formed by an arch-wire engagement surface in the bracket segment and wherein the arch-wire engagement surface is configured to positively engage and orient an arch-wire.

14. An orthodontic appliance, comprising: an indirect bonding tray; at least one bracket segment wherein the at least one bracket segment is integrally formed with the indirect boding tray; an integral slot location feature formed in the at least one bracket segment; wherein said integral slot location feature comprises an arch-wire engagement surface formed in the at least one bracket segment and wherein the arch-wire engagement surface forms a support structure configured to retain an arch-wire; and wherein a weakened section joins the indirect bonding tray and the at least one bracket segment, the weakened section being configured to facilitate removal of the indirect bonding tray from the at least bracket segment after installation of the at least one bracket segment.

15. A method of forming and applying the orthodontic appliance as set forth in claim 1, comprising the steps of: creating a mold of at least one tooth of a patient; forming the indirect bonding tray, at least one bracket segment, and integral slot location feature based on the mold; installing the support structure with the integral slot location feature; installing an arch-wire with the support structure; adhering the at least one bracket segment to the patient's tooth; and separating the indirect bonding tray from the at least one bracket segment at the weakened section.

16. The method of forming and applying the orthodontic appliance as set forth in claim 15, wherein the step of forming the indirect bonding tray, at least one bracket segment, and integral slot location feature comprises 3D printing.

17. The method of creating and installing the orthodontic appliance as set forth in claim 15, wherein the step of forming the indirect bonding tray, at least one bracket segment, and integral slot location feature comprises molding.

18. The method of creating an installing the orthodontic appliance as set forth in claim 15, wherein the support structure is a tube and wherein the step of installing the arch-wire comprises inserting the arch-wire through the tube.

Description

DESCRIPTION OF DRAWINGS

[0032] Reference is now made more particularly to the drawings, which illustrate the best presently known mode of carrying out embodiments of the present disclosure and wherein similar reference characters indicate the same parts throughout the views.

[0033] FIG. 1 is a cross-sectional view of an embodiment of the present disclosure including an indirect bonding tray integrally formed with a bracket.

[0034] FIG. 2 is a perspective view of a completed orthodontic appliance including an indirect bonding tray, brackets, and arch wire according to another embodiment of the present disclosure.

[0035] FIG. 3 is a perspective view of a series of brackets and an arch-wire as installed in accordance with another embodiment of the present disclosure.

[0036] FIG. 4 is a cross-sectional view of another embodiment configured to accommodate multiple arch-wires.

[0037] FIG. 5 is a cross-sectional view of another embodiment including an arch-wire engagement surface.

DETAILED DESCRIPTION

[0038] The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. The following definitions and non-limiting guidelines must be considered in reviewing the description of the technology set forth herein.

[0039] The headings (such as “Introduction” and “Summary”) and sub-headings used herein are intended only for general organization of topics within the present disclosure and are not intended to limit the disclosure of the technology or any aspect thereof. In particular, subject matter disclosed in the “Introduction” may include novel technology and may not constitute a recitation of prior art. Subject matter disclosed in the “Summary” is not an exhaustive or complete disclosure of the entire scope of the technology or any embodiments thereof. Classification or discussion of a material within a section of this specification as having a particular utility is made for convenience, and no inference should be drawn that the material must necessarily or solely function in accordance with its classification herein when it is used in any given composition.

[0040] The citation of references herein does not constitute an admission that those references are prior art or have any relevance to the patentability of the technology disclosed herein. All references cited in the “Description” section of this specification are hereby incorporated by reference in their entirety.

[0041] The description and specific examples, while indicating embodiments of the technology, are intended for purposes of illustration only and are not intended to limit the scope of the technology. Moreover, recitation of multiple embodiments having stated features is not intended to exclude other embodiments having additional features, or other embodiments incorporating different combinations of the stated features. Specific examples are provided for illustrative purposes of how to make and use the apparatus and systems of this technology and, unless explicitly stated otherwise, are not intended to be a representation that given embodiments of this technology have, or have not, been made or tested.

[0042] As referred to herein, all compositional percentages are by weight of the total composition, unless otherwise specified. As used herein, the word “include,” and its variants, is intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that may also be useful in the materials, compositions, devices, and methods of this technology. Similarly, the terms “can” and “may” and their variants are intended to be non-limiting, such that recitation that an embodiment can or may comprise certain elements or features does not exclude other embodiments of the present technology that do not contain those elements or features.

[0043] “A” and “an” as used herein indicate “at least one” of the item is present; a plurality of such items may be present, when possible. “About” when applied to values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters. In addition, disclosure of ranges includes disclosure of all distinct values and further divided ranges within the entire range.

[0044] In comparison to prior appliances and methods of manufacture and application, the present disclosure provides for an orthodontic appliance 10 that is significantly easier to produce and install and is more comfortable to the patient. Embodiments of the present disclosure utilize an indirect bonding tray (“IBT”) 12 that may preferably be, at least in part, 3D printed based on a digital model of a patient's teeth A. Rather than serve simply as a carrier and/or positioning aid for a bracket that is separately formed, the arrangement of the IBT 12 may incorporate at least one bracket segment 22, into its structure. In other words, the bracket segment 22 itself may be formed by 3D printing with the rest of the IBT structure 12 as shown in FIGS. 1 and 2. Rather than simply serving as a mechanism for delivering brackets to a patient's teeth, the combined IBT 12 and bracket segments 22 can also accept a wire 40 component to form a completed orthodontic tooth moving system outside the mouth (in the lab). This whole system can be applied to a patient's teeth in a quick and simple bonding procedure without the need for additional wire insertion procedures.

[0045] The IBT 12 as presented here allows for the possibility of a fully 3D printed appliance and bonding tray combination (integration) which is easy and cost efficient to manufacture. There is no need for separate and independently manufactured brackets. The brackets 20 do not have to be separately, and by hand, manually, and individually installed inside of a separately manufactured IBT. The IBT 12 and bracket segments 22 may be 3D printed or molded with a single material or with multiple materials. For example, it may be desirable to utilize one material for the IBT 12 but another material for the bracket segments 22.

[0046] In addition, the special design of the appliance 10 presented herein provides both easy access for wire insertion and structural support to resist the forces applied by a pre-installed wire 40. Along with the special design of the “closed tube style” brackets 20, which do not require additional ligatures to hold a wire, this provides the option of installing the wire component 40 prior to bonding the brackets to the patient's teeth. In contrast, ligating a wire to a backet inside an IBT is nearly impossible with conventional designs. Therefore, embodiments of the present disclosure provide significant advantages in that (a) it allows for delegation of this procedure outside the doctor's office to a lab technician, (b) it is much easier to work outside the mouth, to see/visualize and access small tight areas with instruments, (c) patient appointments are much shorter, simpler and more comfortable, and (d) it results in increased office productivity and profitability by eliminating in-office procedures.

[0047] Significantly, at least in embodiments in which the bracket segment 22 is formed with the IBT 12, the bracket segment 22 may provide for registered orientation of a support structure 26, which may be, for example, a metal tube, through which an arch-wire 40 may be threaded. As can be seen in FIG. 1, the bracket segment 22 may be provided with a slot location feature 24 in its tooth-facing surface to match a portion of a support structure 26. This slot location feature 24 of the bracket 20 may be readily formed to accommodate any shape of support structure 26, the shape of which may be related to the cross-sectional shape of the desired arch-wire 40. In an exemplary case in which a rectangular metal tube is used as the support structure 26, the bracket slot location feature 24 may be a right-angled indentation in the tooth facing surface of the bracket segment 22. The indentation would properly orient the support structure 24 in a desired position relative to the respective tooth surface. Notably, the slot location feature 24 may be configured to facilitate essentially any facio-lingual angle.

[0048] The incorporation of the support structure 26 provides an opportunity to provide a metal engagement surface for the arch-wire 40. The metal-to-metal surface interaction between the support structure 26 and the arch-wire 40 creates less friction than an interaction with plastic or ceramic. A metal support structure 26 allows for tighter dimensional tolerancing, for example, to 0.001 inches, which is tighter than what is typically possible with printed plastic components. The metal support structure 26 is also more wear resistant, thereby providing more dimensional stability over time. Further, a metal support structure 26 provides a visual contrast relative to the rest of the bracket segment 22, making it easier to visually locate the appropriate insertion point for an arch-wire 40.

[0049] In alternate embodiments, such as shown in FIG. 5, the support structure may be replaced with an arch-wire engagement surface 228 that is molded directly into the bracket segment 222. In the illustrated example, the arch-wire engagement surface 228 is a cavity passing through the bracket segment 222 and has, in this case, a rectangular or square cross-sectional shape corresponding to the arch-wire to be installed. Such embodiments provide an appliance 210 with even fewer parts and, further, eliminates one more step in the construction/installation process for the appliance 210.

[0050] The flexibility of formation of the bracket slot location feature or arch-wire engagement surface in embodiments of the present disclosure may also facilitate including multiple slot location features 124 or arch-wire engagement surfaces in a bracket segment 122 in order to accommodate multiple support structures 126 or direct engagement with multiple arch-wires. Such an arrangement may be used for brackets 120 to be positioned at locations in an appliance 110 where there is a transition from one arch-wire to another (a tooth where two separate arch-wires must be accommodate and allowed to overlap), for example where the appliance 210 transitions from an anterior-wire-segment to a posterior-wire-segment. If suitable for any reason, embodiments of the present disclosure could include bracket segments having multiple slot location features or arch-wire engagement surfaces with each of those slot location features or arch-wire engagement surfaces being shaped to accommodate different forms of support structures and arch-wire configurations.

[0051] An adhesive agent 30 may be utilized in embodiments of the present disclosure. A non-limiting example of a suitable adhesive agent is light-cured dental composite resin. However, whereas in the systems of U.S. Pat. Nos. 8,251,699 and 8,454,359, the adhesive agent comprised as much as 99% of the bracket structure, it may comprise approximately 10% or even less of the bracket 20 structure in embodiments of the present disclosure. The adhesive agent 30 may serve as an adherent for the bracket 20 to the tooth surface in embodiments of the present disclosure. The adhesive agent 30 may also serve as the adherent for the support structure 26 to the slot location feature 24. The adhesive agent 30 may consequently form a small part of the tooth facing surface of the bracket 20.

[0052] As may be recognized by the foregoing description, the bracket 20 resulting from the apparatus and methods described in the present disclosure may be comprised slightly differently in various embodiments of the present disclosure. For example, the bracket 20 may include the bracket segment 22, which is the portion of the bracket 20 that is integrally formed with the IBT 12, by 3D printing as an example, the support structure 26, and the adhesive agent 30, which secures the support structure 26 to the bracket segment 22 and the bracket segment 22 to the tooth surface. In alternate embodiments, the bracket segment 222 may integrally incorporate an arch-wire engagement surface 228 for contact and retention of the arch-wire without need for a separate support structure. In such embodiments, an adhesive agent 230 may generally still be incorporated to secure the bracket segment 222 to the tooth surface.

[0053] During installation of the appliance, the IBT 12 may initially be positioned around the patient's teeth A. However, once the bracket segment(s) 22 integrally formed with the IBT 12 are bonded to the patient's teeth, the remaining portion of the IBT 12 is removed, thereby leaving only the bracket segments 22 in place. Separation of the rest of the IBT 12 from the bracket segment 22 portion of the IBT 12 post-installation may be facilitated by an intentionally weakened section 14 of the IBT 12 in some embodiments. For example, as shown in FIG. 1, a narrowed section may be provided in the IBT along a desired line of separation. In other embodiments, the intentionally weakened section 14 may be perforated.

[0054] Significantly, embodiments of the present disclosure may facilitate installation of the arch-wire 40 in the brackets 20 prior to the IBT 12 being applied to the patient's teeth. For example, an arch-wire 40, or multiple arch-wires if applicable, may be threaded through each of the support structures 26 of a completed IBT 12. This is facilitated, in part, because the support structures 26 may be registered and bonded within the slot location features 24 of the bracket segments 22 with no need for any type of positioning clip that would otherwise occlude the lumen of the support structure 26. In this manner, deliver of bracket segments 22 may combine the previously separate steps of (a) attaching the bracket segments 22 to the patient's teeth and (b) installing the arch-wire 40 in the bracket segments 22. This has not been possible with any previously known appliances. In combining these steps into a single process, the total time associated with installation of the appliance is dramatically reduced, thereby increasing efficiency for the orthodontist and staff and reducing patient discomfort during the installation process. This represents tremendous added value for both orthodontists and their patients. Embodiments in which an arch-wire engagement surface 228 is integrally incorporated into the bracket segment 222 would function similarly.

[0055] Further, embodiments of the present disclosure provide a means for readily creating fully customized brackets for either the lingual A1 or facial A2 tooth surface using digital tools and as a seamless part of the IBT formation. Because the bracket segment 22 is formed as a portion of the IBT 12, which, again, may be 3D printed, this provides the option of creating a fully customized appliance system with the unlimited potential for shaping the bracket segment 22 and the option for unrestricted fully customized orientation of the slot location features 24 or arch-wire engagement surfaces 228 of the bracket segments 22/222, while also decreasing (minimizing) the cost of producing such a highly customized bracket system by other means.

[0056] As can also be seen in FIG. 3, the bracket segment 22 may be formed with an extremely low profile, and with a completely smooth surface as a result of not needing tie-wings for wire retention, in applicable embodiments, with the result that the finished bracket 20 is provided with an extremely small form-factor. Thus, the bracket 20 may be provided with a significantly lower profile than previously possible.

[0057] Because of the extremely low profile, smooth surfaces and esthetically pleasing appearance (being optionally hidden on the tongue side) of embodiments of the present disclosure, these appliances may even be left in the patient's mouth as a replacement for a retainer that may otherwise be recommended after prior art appliances would be removed or for even longer periods of time as a long-term maintenance device. This is made possible because of the minimally obtrusive nature of the brackets 20 that renders them largely unnoticeable to the patient.

[0058] While the formation of embodiments of the IBT 12, including the bracket segments 22 and slot location features 24 or arch-wire engagement surfaces 228, herein has been presented in the context of using 3D printing, it should be appreciated that other manufacturing methods, including more traditional methods such as molding or milling, may also be used.

[0059] The preferred embodiments of the invention have been described above to explain the principles of the invention and its practical application to thereby enable others skilled in the art to utilize the invention. However, as various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings, including all materials expressly incorporated by reference herein, shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present disclosure should not be limited by the above-described exemplary embodiment but should be defined only in accordance with the following claims appended hereto and their equivalents.